Installation, Operating and Service Instructions for FORCE TM • Water Boiler • Cast Iron • Chimney Vent • Gas Fired Models: • FORCE02E • FORCE03E • FORCE04E • FORCE05E • FORCE06E • FORCE07E • FORCE08E • FORCE09E Manual Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pre-installation. . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removing Existing Boiler. . . . . . . . . . . . . . . . .
FORCE E Installation, Operating & Service Manual The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has listed the FORCE E Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://licensing.reg.state.ma.us/pubLic/pl_products/pb_product.asp for the latest Approval Code or ask your local Sales Representative.
FORCE E Installation, Operating & Service Manual 1 Specifications Table 1A: Ratings Boiler Model Number Input1 (MBH) DOE Heating Capacity (MBH) AHRI Net Rating2 (MBH) AFUE FORCE02E 38 32 28 84.0 FORCE03E 68 57 50 84.0 FORCE04E 102 85 74 84.0 FORCE05E 136 114 99 84.0 FORCE06E 170 142 123 84.0 FORCE07E 204 170 148 84.0 FORCE08E 238 199 173 84.0 FORCE09E 272 227 197 84.0 1 Input ratings can be used for elevations up to 2,000 ft.
FORCE E Installation, Operating & Service Manual 2 Pre-installation ! WARNING Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. H. Provide combustion and ventilation air in accordance with the section "Air for Combustion and Ventilation," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes. ! WARNING A.
FORCE E Installation, Operating & Service Manual 3 Removing Existing Boiler A. If an Existing Boiler is Removed: When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
FORCE E Installation, Operating & Service Manual 4 Clearances (continued) Model W FORCE02E 14" FORCE03E 14" FORCE04E 16" FORCE05E 19" FORCE06E 22" FORCE07E 25" FORCE08E 28" Model W FORCE09E 31" Figure 4-1: Minimum Closet Clearances Figure 4-2: Minimum Alcove Clearances * Minimum radial clearance around vent pipe and breeching for single-wall metal pipe vent connector. Otherwise, follow vent connector manufacturer's recommended clearances.
Installation, Operating & Service Manual FORCE E 5 Venting A. Inspect chimney and remove any obstructions or restrictions. Clean chimney if previously used for solid or liquid fuel-burning appliances or fireplaces. B. Locate blocked vent switch on boiler draft hood. Verify connections are made. C. Install Vent Damper OPEN THE VENT DAMPER CARTON and remove Installation Instructions. READ INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding.
FORCE E Installation, Operating & Service Manual 5 Venting (continued) c. Draft diverter outlet/vent damper is greater than 4 in. in diameter. 5. Vent pipe should have greatest possible initial rise above draft diverter consistent with head room available and required clearance from adjacent combustible building structure. Vent pipe should be installed above bottom of chimney to prevent blockage. 6. Slope vent pipe upward from draft diverter to vent terminal not less than 1/4" per foot.
FORCE E Installation, Operating & Service Manual 5 Venting (continued) Roof Slope Heights Figure 5-3 : Termination Location for Gas Vent 109444-03 - 12/19 Roof Slope ft. Flat to 6/12 1.0 Over 6/12 to 7/12 1.25 Over 7/12 to 8/12 1.5 Over 8/12 to 9/12 2.0 Over 9/12 to 10/12 2.5 Over 10/12 to 11/12 3.25 Over 11/12 to 12/12 4.0 Over 12/12 to 14/12 5.0 Over 14/12 to 16/12 6.0 Over 16/12 to 18/12 7.0 Over 18/12 t 20/12 7.5 Over 20/12 to 21/12 8.
FORCE E Installation, Operating & Service Manual 6 Water Piping ! WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or building. A. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Oxygen contamination sources are system leaks requiring addition of makeup water, fittings, and oxygen permeable materials in distribution system.
109444-03 - 12/19 System Circulator Unions IWH Circulator Flow Check Full Port Isolation Valve Expansion Tank Backflow Preventer Cold Water Return IWH Return Indirect Water Heater (IWH) Full Port Isolation Valve Unions Full Port Isolation Valves Figure 6-3: Recommended Water Piping Direct Connection System (left side) Optional Zone Valve Controlled System System Zone Valves To System Optional Circulator Zone Controlled System Zone Circulators IWH Supply Fill Valve Drain Valve Safety Rel
System Circulator Optional Zone Valve Controlled System System Zone Valves To System Optional Circulator Zone Controlled System Zone Circulators Flow Check To System Full Port Isolation Valves Expansion Tank Backflow Preventer Cold Water Return Fill Valve IWH Return Safety Relief Valve Pipe within 6" of floor or drain Drain Valve Full Port Isolation Valves Drain Valve Circulator Full Port Isolation Valves Indirect Water Heater (IWH) Full Port Isolation Valve Unions 'A' From Syste
FORCE E Installation, Operating & Service Manual 7 Gas Piping A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Minimum gas valve inlet pressure is listed on rating label. See Table 7-1. Table 7-1: Gas Pressure Natural Gas Inlet Min (in. wc.) Inlet Max (in. wc.) Manifold (in. wc.) All Sizes 4.5 14.0 3.5 LP Inlet Min (in. wc.) Inlet Max (in.
FORCE E Installation, Operating & Service Manual 8 Electrical ! WARNING Electrical Shock Hazard. Wiring errors can cause improper or dangerous operation. Verify proper operation after installation. A. Install wiring so boiler is electrically bonded to ground in accordance with requirements of authority having jurisdiction, or in absence of such requirements, with the National Electrical Code, ANSI/NFPA 70. B. Install thermostat. Locate on inside wall approximately 4 feet above floor.
FORCE E Installation, Operating & Service Manual 8 Electrical (continued) Figure 8-1: Wiring Connection Diagram 109444-03 - 12/19 15
FORCE E Installation, Operating & Service Manual 8 Electrical (continued) Figure 8-2: Schematic Ladder Diagram 16 109444-03 - 12/19
Installation, Operating & Service Manual FORCE E 9 System Start-Up and Checkout A. Visual Main Burner Check Inspect burners for dislodgement during shipment. Rear of burners should be in vertical slots in rear of burner tray and front of burners should be seated completely on orifices. 4. Attach hose to drain valve located on return piping (see Figure 6-3 and 6-4). Note-Terminate hose in five gallon bucket, at a suitable floor drain, or outdoor area). 5.
FORCE E Installation, Operating & Service Manual 9 System Start-Up and Checkout (continued) Figure 9-1: Operating Instructions 18 109444-03 - 12/19
FORCE E Installation, Operating & Service Manual 9 System Start-Up and Checkout (continued) F. Perform limit check 1. Ensure gas to boiler is off 2. Set ROOM THERMOSTAT to lowest setting. 3. If limits are functioning properly (LWCO, flame rollout switch, blocked vent switch, damper), boiler should spark. If boiler does not spark, see Section 14 "Troubleshooting" for guidance. 4. Turn "OFF" the electric switch to boiler. G. Start boiler according to "Operating Instructions" in Figure 9-1. H.
FORCE E Installation, Operating & Service Manual 9 System Start-Up and Checkout (continued) J. Check Main Burner Flame (see Figure 9-5) 1. NORMAL FLAME: a. Clearly defined inner cone with no yellow tipping. b. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. 2. ABNORMAL FLAME (if found, check inlet and outlet gas pressure. Procedure found in following steps): a. Overfired - large flame b. Underfired - small flames c.
FORCE E Installation, Operating & Service Manual 9 System Start-Up and Checkout (continued) appliance main burners are operating. P. Check ignition system safety shut-off device. After control has finished sparking, remove ignitor/ flame sense wire from control. Burners will shut down. Q. Test LWCO functionality Press "TEST"/SETTINGS button on Hydrostat 3200. Boiler should shut down. • Set thermostat to call for heat and push “TEST”/SETTINGS button on Hydrostat 3200 to simulate low water condition.
FORCE E Installation, Operating & Service Manual 10 Operation A. Temperature Limit/LWCO Control Refer to HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. B. Electronic Ignition Module See Figure 10-1 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. Table 10-2 cross-references ignition module terminal designations to ignition terminal numbers in wiring ladder diagrams.
FORCE E Installation, Operating & Service Manual 10 Operation (continued) v. Check pilot flame. It must be blue, steady and envelop flame sensing rod 3/8” to ½”. vi. If needed, adjust pilot flame by turning the gas valve pilot adjustment screw clockwise to decrease or counterclockwise to increase pilot flame. Always reinstall pilot adjustment screw cover and tighten securely upon completion to assure proper gas valve operation. g.
FORCE E Installation, Operating & Service Manual 11 Before Leaving Jobsite Before Leaving Jobsite: Boiler and system filled with water Performed gas leak test Checked pilot burner flame Checked main burner flames Checked gas input rate Checked gas inlet pressure Checked gas manifold pressure Checked CO level in vent Checked vent damper operation Check ignition system safety shut-off device Tested LWCO functionality Tested high limit operation Tested addit
FORCE E Installation, Operating & Service Manual 12 Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
FORCE E Installation, Operating & Service Manual 12 Service and Maintenance (continued) ! WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. • Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.
FORCE E Installation, Operating & Service Manual 12 Service and Maintenance (continued) D. Clean Main Burners and Firebox. 1. To remove burners for cleaning, changing orifices, or repairs: a. Remove Jacket Front Panel. b. Disconnect pilot tubing at gas valve. c. Disconnect 3-wire plug at the gas valve. d. Remove wires to flame roll-out switch. e. Disconnect ignitor sensor cable at boiler control. f. Remove the burner access panel. g.
FORCE E Installation, Operating & Service Manual 12 Service and Maintenance (continued) Q. Test Vent Damper Operation Vent damper must be in open position when main burners are operating. R. Test Functionality of LWCO See "Start-up and Checkout - Check LWCO Functionality. S. Check High Limit Control See " Start-up and Checkout - Check High Limit Control". T. Check Thermostat Operation See "Start-up and Checkout - Check Thermostat Operation" U. Check CO detector operation (if available). V. Lubrication.
FORCE E Installation, Operating & Service Manual 13 How It Works FORCE E boilers are equipped with Hydrostat 3200 and Honeywell S8610M Ignition module. Hydrostat 3200 contains features such as high limit switch, LWCO and circulator relay. Energy is saved by using a thermal target feature which adjusts boiler target temperature depending on heat required. Honeywell S8610M provides ignition control.
FORCE E Installation, Operating & Service Manual 13 How It Works (continued) 3 Rear of Boiler 7 (On rear of boiler) 3 1 2 5 4 30 6 109444-03 - 12/19
FORCE E 14 Troubleshooting Installation, Operating & Service Manual A. Before Troubleshooting When troubleshooting boiler, keep in mind: 1. Troubleshooting should be completed by a professional heating technician. 2. Before seeking technical assistance, the servicing technician should have an electrical meter and gas pressure gauge available for use. 3. Check electrical connections on boiler before proceeding (see Figure 8-1 and Figure 8-2). 4.
FORCE E Installation, Operating & Service Manual 14 Troubleshooting (continued) Start Before troubleshooting, familiarize yourself with the Startup and Checkout procedures. Note: "Call for heat" 24 VAC supply is connected to the 24 V terminal on the control. Turn gas supply off. Turn thermostat (controller) to "Call For Heat". Power to module? (24 V normal) No Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring.
FORCE E Installation, Operating & Service Manual 15 Service Parts All FORCETM E Series Service Parts may be obtained by contacting your local Ferguson branch. Key No.
FORCE E Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
FORCE E Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
FORCE E Installation, Operating & Service Manual 15 Service Parts (continued) Part Number [Quantity] FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E Key No.
FORCE E Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
FORCE E Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
FORCE E Installation, Operating & Service Manual 15 Service Parts (continued) 7B 7A 7C Part Number [Quantity] Key No. Description 7A Power Supply Harness 109963-01 [1] 7B Main Control Harness 109957-01 [1] 7C Ignition Harness 109953-01 [1] FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Accessories: Key No.
FORCE E Appendix: Installation, Operating & Service Manual Combination Refrigeration/ Heating System A. If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure A-1. Also consult Residential Hydronic Heating Installation and Design I=B=R Guide. Supply main to combined heating & cooling system B.
FORCE E Appendix: Installation, Operating & Service Manual Low Return Water Temperatures Thermal Shock: Cast iron boilers are very robust. 110oF and below return water temperatures will not cause thermal shock to castings. Condensation is a different matter: Cast iron boilers will tolerate intermittent periods of condensation, but are not designed for extended condensation periods. Water temperatures below 120oF cause condensation that damage cast iron, burners and other components.
FORCE E Appendix: Installation, Operating & Service Manual Low Return Water Temperatures (continued) Primary-Secondary Pumping: This is an improvement over simple by-pass piping to reduce condensation. Again this is a fixed system. It can not adapt to variations in temperature and flow. Best Alternative: System by-pass kit [part number 107795-01] that addresses these situations. A strap on temperature sensor measures boiler inlet temperatures.
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FORCE E 44 Installation, Operating & Service Manual 109444-03 - 12/19
